Sleeve Valve

ABSTRACT

An extractor and a method using the extractor for extracting active principle from solid materials using an extracting fluid, said extractor comprising among others an extractor column ( 1 ), having a first side ( 22 ), a second side ( 23 ), a top side ( 24 ), and a bottom side ( 25 ); a top plate ( 10 ) for sealing the said extractor column ( 1 ), said top plate ( 10 ) positioned at said top side ( 24 ), at least one perforated plate ( 4 ) having projections ( 5 ); wherein said perforated plate ( 4 ) is positioned inside said extractor column ( 1 ) by means of a screw shaft ( 3 ), wherein said screw shaft ( 3 ) passes through said top plate ( 10 ) by means of a leak proof joint ( 12 ); wherein said joint ( 12 ) allows rotation of said screw shaft ( 3 ).

TECHNICAL FIELD

The present disclosure relates to an extractor useful for extraction of active principle from solid sources using an extracting fluid. The present disclosure provides process of extraction of active principles using said extractor.

BACKGROUND AND PRIOR ART

The extraction of valuable active principles from natural sources using simple and efficient extraction system is an important required attribute towards the development of new therapeutic and agricultural products. The present invention of extractor systems is useful to extract high value substances from natural bioresources such as crustacean shells, seaweed, and agricultural crops, wild and modified plants. The present invention is applicable in the pharmaceutical, perfumery and cosmetics, food and food processing, bio-technological and chemical industries for the extraction of valuable extractive products from the said solid materials.

DE 3,318,317 discloses a process and an apparatus in which the still undamaged, that is not yet disintegrated product and the extraction liquid are, separately, subjected to an elevated gas or air pressure. The extraction liquid, after a predetermined time of action, is brought into contact with the product with the pressure being maintained. The pressure is then suddenly relaxed, the cells of the products are destroyed and the aroma substances or the like being liberated, which are then taken up directly by the extraction liquid and after a predetermined time of action and, if required, with mechanical filtration, are led off without loss.

U.S. Pat. No. 2,045,981 (C1) discloses a continuous extractor for solid body liquid system for extraction of organic products. The system has two units for charging raw material and extractant, each having hermetically sealed body and rotor with circumferentially positioned receptacles for charging liquid and solid materials.

U.S. Pat. No. 2,091,120 (C1) discloses extractor for solid liquid system, which includes vertical cylindrical housing with technological branch pipes and thermostating jacket. Extractor is also provided with baffles mounted over periphery and agitator mounted co-axially in housing with elliptic filter element secured onto it co-axially; filter element separates extract collecting chamber in its lower portion.

U.S. Pat. No. 5,776,317 discloses extractor for soxhlet solid liquid extraction, consisting of extraction vessel to which reflux line is molded in one piece. Solvent is vaporized in a heatable distillation vessel and routed via a steam line into an extraction vessel located above the distillation vessel. The extraction vessel is provided to hold the material to be extracted and the extract and is made with a cooler for condensing the solvent or extractant.

WO 83/02571 discloses an extractor for the liquid solid extraction of extractive materials from natural substances comprising a support frame hinged about an axis parallel to a fitting floor and arranged in housing. It consists of rotary devices of different types acting on the extraction mass, such as suction, agitation and coating devices. The devices are capable or rotating about an axis perpendicular to the fitting floor.

In the prior art perforated plate have been used in extractors. The extractor system comprising of perforated plates has been disclosed in U.S. Pat. No. 4,634,578, U.S. Pat. No. 4,748,006 and U.S. Pat. No. 4,258,011. The perforated plate used in the liquid-liquid extractors disclosed in U.S. Pat. No. 4,634,578, U.S. Pat. No. 4,748,006 are non-retaining plate, and are used for better mixing of two liquid phases used in the extraction. These extractors do not involve the solid material. The perforated plate disclosed in the U.S. Pat. No. 4,258,011 is a supporting plate for solid material.

U.S. Pat. No. 4,258,0211 discloses apparatus for extraction of vegetable solids by treatment of solvents, which comprises movable perforated plate to support the solid material and the solvents are percolated through the solid bed downwardly.

U.S. Pat. No. 4,464,758 discloses reciprocating plate liquid-liquid extractor column having a plates therein and means to operably connected thereto for imparting reciprocating motion to said plates. The extractor is not intended for solid liquid extraction.

U.S. Pat. No. 4,748,006 disclose vertical wall liquid-liquid extractor having reciprocating perforated plates in mixing zone. The extractor is not intended for solid liquid extraction.

The references incorporated herein disclose the extractor system with stirring or agitating devices, or with the heating of extractant liquid so as to extract the active principle/s from the solids.

SUMMARY

The present disclosure provides an extractor for extracting active principle of interest from solid materials using an extracting fluid. The extractor comprises of an extracting column having at least one perforated plate with projections that is useful for compacting, crushing the solid material, leveling of solid material, and allowing passage of extracting fluid through perforations without allowing solid material to leave the extractor. The pressure applied for the compaction of solid material is by means of screw shaft which in turn is operated by a manual, hydraulic or motorized drive. The extractor further comprises an inlet for extracting liquid which allows the liquid to come in contact with the solid material thereby resulting in extraction of active principles of interest contained in the solid material. The extractor further comprises outlets for collecting extracting fluid containing extracted active principle and also residual extracting fluid.

The present disclosure provides an extractor that has several advantages. The extractor allows better contacting of extracting fluid with solid material due to compacted bed of solid, enhanced flow distribution of extracting fluid. The extraction operation that occurs in the extractor is equivalent to multiple contacts of solids with liquid leads to complete extraction of desired active principle. The extractor provides higher extracting efficiency and productivity per unit extracting medium and time. The solid material is continuously exposed to fresh extracting medium, leading to fast extraction (there no equilibrium stage like batch extractor). There is less consumption of extraction medium. The extractor can be used for extraction of volatile, non-volatile, polar, non-polar active principles. The extractor causes higher average extraction yields of more than about 95% compared to other extractors and is also easy to operate.

The present disclosure also provides the process of extracting important active principle/s from solid materials by using the extractor.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

The features, objects and advantages will be evident from the following description of the preferred embodiments of the present disclosure taken in conjunction with the accompanying drawing in which;

FIG. 1 is a schematic illustration of the Extractor.

FIG. 2 a is side view of the perforated plate 4 with projections 5 and perforations 26.

FIG. 2 b is the vertical cross section of perforated plate 4 showing different types of perforations such as 26 a and 26 b.

DETAILED DESCRIPTION

The present disclosure relates to an extractor for extracting active principle from solid materials using an extracting fluid, said extractor comprising a vertical vessel or column, a means to feed the solid material into the extractor adjacent to the top side of the extractor, and a means to compact or pack the fed solid material into the extractor. The system used for compacting or packing of the solid materials into the extractor consists of a plate, preferably perforated and with downward projections, and is operated through a screw type shaft that can move up or down by an external drive, wherein the drive is either manual drive or motorized drive or hydraulic system. The extracting liquid enters into the extractor through an inlet located at the down side (bottom end) of the extractor and passes through a perforated supporting plate, which distributes the liquid evenly in to the extractor, extracts the said active principles from the said solid material/s, and is taken out from the outlet adjacent to the top side of the extractor column. The residual liquid remaining inside the extractor after complete extraction is removed by a hot air or steam passed into the extractor and is collected through the second outlet adjacent to the top end of the extractor via a condenser system attached to the said second outlet. The solids packed in the extractor after complete extractions are removed from the bottom of the extractor, wherein the bottom plate and perforated supporting plate are opened manually using a hinge joint or through a motorized system.

In the present disclosure, the term solid material refers to the raw material from which the active principles are extracted.

In the present disclosure, the term extracting fluid and extractant are synonymous and is used interchangeably hereinafter. The extracting fluid refers to a fluid that extracts active principles from said solid material.

In the present disclosure, the term compaction refers to application of pressure.

In the present disclosure, the term top column sealing plate and top plate is synonymous and is used interchangeably hereinafter.

In the present disclosure, the term Bottom Supporting plate and bottom plate is synonymous and is used interchangeably hereinafter.

In the present disclosure, the term extractor refers to a solid liquid extractor where a fluid on coming in contact with solid materials extracts active principles from the solid material. The extraction of active principles by extracting fluid results from solubility of active principles in the fluid which then is collected form the extractor. The term extractor, compacted upflow solid liquid extractor, compacted upflow extractor are synonymous and is used interchangeably herein after.

In the present disclosure, the singular forms “a”, “an”, and “the” include plural reference also unless the context clearly dictates otherwise. Thus, for example, a reference to “active principle” includes singular or a plurality of such active principles, and a reference to “an extracting fluid” is a reference to one or more extracting fluid and equivalents thereof known to those skilled in the art. Similar syntactical principal also applies to other examples such as solid material, solvent, plate and perforated plate.

The present disclosure provides an extractor for efficient extraction of active principles from solid material by an extracting liquid. The extractor of the present disclosure comprises of an extractor column 1, an inlet to feed solid material 2, Screw shaft 3, Perforated plate 4, Projections 5 attached to perforated plate 4, Solid material 6, Perforated support plate 7, Extracting fluid inlet located at the bottom side of the extractor 8, Liquid outlet 9, Top column sealing plate 10, Drive (manual, motorized or hydraulic) 11, Leak proof joint 12, Condenser 13, Solid material entry point 14, Hinge or hinge like arrangement 15, Bottom Supporting plate 16, Outlet 17 (for vapors, air, gas, steam or volatile matter), Lid for solid inlet 18 and. The diagrammatic representation of the extractor of the present disclosure is provided in FIGS. 1 and 3.

In an embodiment of the present disclosure provides an extractor as shown in FIGS. 1 and 3 that comprises of a cylindrical extractor column 1 in which a perforated supporting plate 7 is incorporated at the bottom end to distribute the incoming liquid or air or gas or steam evenly in to the extractor column. The solid material for extraction 14 is fed through inlet 2 located near the top of the extractor. The solid matter is fed in one lot, or many lots, and compacted by moving the slowly rotating perforated plate 4, provided with projections 5, the movement carried out through a screw shaft 3 and a drive (manual, motorized or hydraulic) 11. The perforated plate 4 with projections 5 performs multiple functions such as compacting and/or crushing the solid material, leveling of solid material, and allows the passage of extracting liquid through perforations without allowing solid material to leave the extractor. The compaction or packing of said solid material using the perforated plate 4 with projections 5 leads to good contact of said extracting fluid with said solid material 6, an hence good efficiency. The screw shaft 3 operates through a leak proof joint 12 held in place by top column sealing plate 10 and allows the screw shaft to rotate freely. The extracting liquid enters into the extractor column through inlet 8 and passes in upward direction through distributor 7 held in position by a supporting plate 16. The said extracting liquid extracts the active principle from the said solid material 6 while moving in upward direction and is taken out through the outlet 9 located towards first end of the extractor. The extracting liquid is either continuously passed through the extractor till the complete exhaustion of said solid material in the active content, or is re-circulated for complete extraction of said active principles from the said solid material, and is then displaced by fresh liquid. The residual extracting liquid is removed from the extractor by passing steam or air (preferably hot air or gas) through bottom inlet 8 and collecting the solvent as a condensate from condenser 13 attached to the outlet 17 adjacent to the first end of the extractor. While removing the residual extracting liquid as discussed above, the solid inlet 2 is closed using a lid 18. Alternatively, if a gas or steam is being used as extractant, it is passed upwards with solid inlet 2 closed, and the vapor passed through the condenser 13. The extracted or exhausted solid material is removed from the bottom of the extractor, by opening the bottom plate 16 which is moved manually through a hinge or hinge like arrangement 15, or is opened using motorized drive mechanism. The valves 19, 20 and 21 are used at the different inlet and outlet for maintaining flow of the extracting fluid and may be operated manually or automatically.

In an embodiment of the present disclosure, the extractor used for extraction of active principle from solid material by an extracting fluid comprises a jacket as provided in FIG. 3 for cooling or heating of the extractor and increasing the extraction efficiency of the extractor.

An embodiment of the present disclosure provides an extractor for extracting active principle from solid materials using an extracting fluid, said extractor comprising; a extractor column 1, having a first side 22, a second side 23, a top side 24, and a bottom side 25; a top plate 10 for sealing the said extractor column 1, said top plate 10 positioned at said top side 24; a bottom plate 16 positioned at said bottom side 25 of said extractor column 1 by means a hinge arrangement 15; a solid material inlet 2 for feeding the solid material in said extractor column 1, wherein said solid material inlet 2 is located at said first side 22 towards said top side 24 of the extractor column 1; a extracting fluid inlet 8 is for introducing said extracting fluid in said extractor column 1, wherein said extracting fluid inlet 8 is located at bottom side 25 of said extractor column 1, at least one perforated plate 4 having projections 5; wherein said perforated plate 4 is positioned inside said extractor column 1 by means of a screw shaft 3, wherein said screw shaft 3 passes through said top plate 10 by means of a leak proof joint 12; wherein said joint 12 allows rotation of said screw shaft 3; a perforated supporting plate 7 supported by said bottom plate 16, wherein said perforated supporting plate 7 distributes the extracting fluid evenly in said extractor column 1; a first outlet 9 (liquid outlet) positioned at said first side 22 towards said top side 24 of said extractor column 1; wherein said extracting fluid containing said active ingredient extracted from said solid matter is collected from said extractor column 1 through said first outlet 9; and an optional second outlet 17 for removing air, gas, steam or residual extracting fluid after removal of said extracting fluid containing said active principle from said first outlet 9.

An embodiment of the present disclosure provides that compaction leads to packing of more solid material inside the column, which directly affects the productivity per cycle of the extractor. During compaction, crushing/grinding occurs due to projections 5 on the perforated plate 4. Pressure applied to the solid material compacts the solid material. This does not pressurize the incoming liquid or extractant. The compacted solid material ensures the even flow distribution of the extracting liquid. Compacted bed of solid material 6 avoids the channeling and misdistribution of the extractant. Thus, the better contacting of solid material with incoming liquid and enhanced efficiency of the extractor results in unexpected complete extraction of active principle from the solids. This also leads to the reduced solvent/extractant consumption in the process. Overall, the compaction of solids ensures the increased yield and productivity with better economy of the operation.

Another embodiment of the present disclosure provides an extractor with perforated plate 4 that has perforations of diameter in the range of 0.5 mm-50 mm.

Another embodiment of the present disclosure provides an extractor with at least one perforated plate 4 that has perforations of diameter in the range of 0.5 mm-20 mm.

Yet another embodiment of the present disclosure provides an extractor with at least one perforated plate 4 that has perforations that cover % surface area of said perforated plate 4 in the range of 0.001% to 20%.

Still another embodiment of the present disclosure provides an extractor that has projections 5 on said perforated plate 4 is in the range of 1-20 per square feet.

Further another embodiment of the present disclosure provides an extractor with projections 5 having diameter in the range of 2 mm-50 mm.

In another embodiment, the present disclosure provides an extractor with projections 5 having length in the range of 20 mm-500 mm.

Another embodiment of the present disclosure provides an extractor with projections 5 have length in the range of 20 mm-300 mm.

Still another embodiment of the present disclosure provides an extractor with blunt end projections 5.

Another embodiment of the present disclosure provides an extractor with sharp end projections 5.

In further another embodiment, the present disclosure provides an extractor with sharp end and blunt end projections 5.

Another embodiment of the present disclosure provides an extractor wherein projections 5 on the perforated plate 4 have blunt end and/or sharp end. A suitable permutation and combination of blunt end and sharp end projections 5 may be used depending upon type of solid material fed to the extractor.

Another embodiment of the present disclosure provides an extractor with projections 5 arranged on said perforated plate 4 at an angle in the range of 30°-90°.

Still another embodiment of the present disclosure provides an extractor with projections 5 arranged on said perforated plate 4 at an angle of 30°.

Yet another embodiment of the present disclosure provides an extractor with projections 5 arranged on said perforated plate 4 at an angle of 40°.

In another embodiment, the present disclosure provides an extractor with projections 5 arranged on said perforated plate 4 at an angle of 50°.

Another embodiment of the present disclosure provides an extractor with projections 5 arranged on said perforated plate 4 at an angle of 60°.

Further another embodiment of the present disclosure provides an extractor with projections 5 arranged on said perforated plate 4 at an angle of 70°.

Another embodiment of the present disclosure provides an extractor with projections 5 arranged on said perforated plate 4 at an angle of 80°.

Another embodiment of the present disclosure provides an extractor with projections 5 arranged on said perforated plate 4 at an angle of 90°.

In another embodiment, the present disclosure provides that the projections 5 on the perforated plate 4 performs multiple functions such as leveling of solid material, crushing/grinding the solid material, compaction of solid material, and allows the passage of extracting fluid through perforations without allowing solid material to leave the extractor. The pressure applied for the compaction is by means of screw shaft which in turn operated by a manual, hydraulic or motorized drive.

In another embodiment, the present disclosure provides that the projections 5 contribute to the better compaction of the solid material along with the perforated plate 4. On the surface of perforated plate 4 any permutation and combinations of size of projections 5 can be used depending upon the type of solid material. The compaction or packing of said solid material using the perforated plate 4 with projections 5 surprising leads to better contact of said extracting fluid with said solid material 6, an hence good efficiency. The unexpectedly high yield of the active principle is obtained by using the extractor of the present disclosure as exemplified in Examples 3-6.

In another embodiment of the present disclosure provides an extractor wherein perforated supporting plate 7 has perforations of diameter in the range of 0.5 mm-10 mm.

Another embodiment of the present disclosure provides an extractor wherein said perforated supporting plate 7 has perforations that cover % surface area of said perforated supporting plate 7 in the range of 0.001% to 10%.

Another embodiment of the present disclosure provides a perforated supporting plate 7 that supports the solid material as well as avoids the formation of jet of extracting liquid through the solid material packed inside the column. This aids in the better flow distribution of incoming extracting fluid.

Yet another embodiment of the present disclosure provides an extractor wherein said screw shaft 3 is connected to an external drive 11.

Still another embodiment of the present disclosure provides an extractor wherein said external drive 11 is a manual drive, motorized drive or hydraulic drive.

Another embodiment of the present disclosure provides an extractor wherein any residual extracting fluid is removed in vapor form.

Another embodiment of the present disclosure provides an extractor that has a second outlet 17 connected to a condenser 13 for collecting the volatile active principles, residual solvents, residual extracting fluid that is removed by purging hot air, stream or gas.

Another embodiment of the present disclosure provides an extractor that has a solid material inlet 2 with a closing lid 18.

Another embodiment of the present disclosure provides an extractor where solid material used for extraction of important active principles is a natural source, transgenic plant source, transgenic animal source, genetically manipulated or hybrid varieties of natural source.

Another embodiment of the present disclosure provides an extractor wherein said solid materials is includes but is not limited to plant source, herb source, shrub source, sea weeds source, animal and insect source.

Another embodiment of the present disclosure provides an extractor wherein said active ingredient is a primary metabolite or a secondary metabolite.

Another embodiment of the present disclosure provides an extractor wherein said active principle includes but is not limited to a therapeutic drug, insecticide, growth regulator; flavor, perfumes, protein, peptide and nucleic acid.

Further, another embodiment of the present disclosure provides an extractor wherein said active principle is a therapeutic drug that includes but is not limited to glycosides, alkaloids, vitamins, coumarins and flavonoides.

In yet another embodiment, the present disclosure provides that the active principle extracted using the extractor of the present disclosure is non-volatile or volatile matter.

Another embodiment of the present disclosure provides an extractor wherein said active principle extracted using the extractor of present disclosure is exemplified by artemisinin, stevioside, citronella oil, scopoletin, soya protein, artemisinin and psilocybin as provided in examples 3-6.

Another embodiment of the present disclosure provides an extractor wherein said extracting fluid is liquid, gas, air, steam or supercritical fluid.

Another embodiment of the present disclosure provides an extractor wherein said liquid is selected from a group consisting of polar solvent, non-polar solvent, ionic solvent or mixture thereof.

Another embodiment of the present disclosure provides an extractor wherein said liquid is a polar solvent selected from a group consisting of dimethyl formamide, tetrahydrofuran, water, acetonitrile, isopropanol, diethyl ether, 1-4 dioxane, alcohol, ketone and combinations thereof.

Further, in another embodiment of the present disclosure, the polar solvents cover acids, bases and/or buffers. The acids include but are not limited to organic acids such as acetic acid, citric acid, tartaric acid and mineral acids such as sulfuric acid, hydrochloric acid, phosphoric acid. The bases include but are not limited to sodium hydroxide, potassium hydroxide, calcium hydroxide, ammonium hydroxide and salts of sodium, ammonium, potassium, calcium as a citrate, tartarate, acetate, borate, phosphate and sulphate. The other buffers include but are not limited to Tris (tris(hydroxymethyl)methylamine) buffer, MOPS (3-(N-morpholino)propanesulfonic acid) buffer, Bicine (N,N-bis(2-hydroxyethyl)glycine) buffer and any combinations thereof.

Another embodiment of the present disclosure provides an extractor wherein said liquid is a non-polar solvent selected from a group consisting of but not limited to hexane, heptanes, pentane, cyclohexane, benzene, toluene, carbon tetra chloride, butyl acetate, ethyl acetate, methylene dichloride, ethylene dichloride, chloroform, other chlorinated organic solvents and combinations thereof.

Another embodiment of the present disclosure provides an extractor wherein said liquid is an ionic solvent that includes but is not limited to N,N-dimethylethanolammonium octanoate (DMEA oct) and bis(2-methoxyethyl)ammonium bis(trifluoromethylsulfonyl)imide (BMOEA bst).

Another embodiment of the present disclosure provides an extractor wherein said extracting fluid is hexane, water, steam, hexane-methylene dichloride, ethanol or methanol.

Another embodiment of the present disclosure provides an extractor wherein said gas is supercritical carbon dioxide or supercritical water.

Another embodiment of the present disclosure provides a process of extracting active principle from solid material by an extracting fluid using said extracting column, said process comprising; feeding said solid material into said extractor column 1 by said solid material inlet 2; compacting said solid material by said perforated plate 4 having said projections 5, wherein said compacting of solid material by said perforated plate 4 is performed by exerting pressure on said perforated plate 4 by said screw shaft 3; wherein said screw shaft 3 is driven by said external drive 11; introducing said extracting fluid into said extractor column 1 through said extracting fluid inlet 8; distributing said extracting fluid in the said extractor column 1 by said perforated supporting plate 7; contacting said compacted solid material with said extracting fluid; collecting said extracting fluid containing said active principle extracted from said solid material through said first outlet 9; optionally removing residual extracting fluid from said extractor column through said second outlet 17; wherein removing of said residual extracting fluid is performed by introducing steam or gas through said extracting fluid inlet 8 and closing said lid 18; ejecting out said residual extracting fluid in vapor form through said second outlet 17; and removing solid material from said extractor column 1 by opening said bottom plate 16.

When the extracting fluid is pumped into the extractor, the medium extracts the active principles from the compacted bed of solid material. The products (active principle) having solubility in the extracting fluid diffuses from solid material into the extracting fluid. Continuously flowing extracting fluid carries the extracted product/s (active principle) into it, which is collected at the outlet 9 or 17 of extractor.

An embodiment of the present disclosure provides that the active principle extracted using said extractor may be processed directly or after subjecting the active principle to an initial treatment by processes that include but not limited to evaporation, distillation, liquid-liquid extraction or dilution by known techniques such as adsorption, chromatography, centrifugation, filtration, direct precipitation, direct crystallization or fractional crystallization for further purification or polishing of the active principle extracted in the extractor.

An embodiment of the present disclosure provides that the solid material used for extraction of active principle can contain different products or set of products having different physico-chemical properties. The different active principles can be extracted by different set of solvent/s such as different combination of solvents to extract them separately so as get products with enhanced purity, which ease out the further purification of desired product/s. Therefore, extraction of more than one active principle from a solid material with ease, enhanced yield and enhanced purity is an additional advantage of the extractor.

Another embodiment of the present disclosure provides a process of extracting active principle from solid material by an extracting fluid using said extracting column, wherein the duration after which the final extract containing active principle is ousted from the outlet 9 is determined by the flow velocity of the extracting medium. The velocity used from extraction depends on the solubility parameters of active principle, nature and type of solid material from which it is to be extracted, diameter of extractor, and diffusivity of the active principle into the extracting medium.

Another embodiment of the present disclosure provides a process of extracting active principle from solid material wherein said solid material fed to the extractor is optionally pre-pulverized, pre-micronized, pre-grinded or pre-crushed. This optional pre-processing of said solid material before feeding into the extractor column 1 may firstly ease out the process of feeding through solid material inlet 14 and may also improve extraction of active principle.

Another embodiment of the present disclosure provides a process of extracting active principle from solid material by an extracting fluid using said extractor wherein said extracting fluid has a flow velocity in the range of 10-10000 cm/hr.

Further, another embodiment of the present disclosure provides a process of extracting active principle from solid material by an extracting fluid using said extractor wherein said solid material may be feed into the extractor column 1 either manually or automatically with belt or bucket conveyors.

Another embodiment of the present disclosure provides a process of extracting active principle from solid material by an extracting fluid using said extracting column wherein said extracting fluid has a flow velocity in the range of 50-5000 cm/hr.

Another embodiment of the present disclosure provides a process of extracting active principle from solid material by an extracting fluid using said extracting column wherein said pressure used for compacting solid materials is in the range of 0.5-50 bar.

Another embodiment of the present disclosure provides a process of extracting active principle from solid material by an extracting fluid using said extracting column wherein said pressure used for compacting solid materials is in the range of 2-30 bar.

Another embodiment of the present disclosure provides a process of extracting active principle from solid material by an extracting fluid using said extracting column wherein said process is useful for extracting single or multiple active principle.

Another embodiment of the present disclosure provides a process of extracting active principle from solid material by an extracting fluid using said extracting column wherein said process is useful for extracting a therapeutic product; intermediate for the production of therapeutic product; valuable agricultural product such as insecticide, growth regulator; product with cosmetic value such as flavor/perfumes.

In another embodiment, the present disclosure provides a process of extracting active principle from solid material by an extracting fluid using said extracting column wherein said process is useful for molecules present in the natural sources; expressed or over expressed products in the said natural sources or in any part of these natural sources by genetic manipulation/engineering or other methods known to those skilled in art.

In another embodiment the extractor of the present disclosure that is useful for extraction of single or multiple product(s) of interest from sources in pure, partially pure or impure form.

Thus the potential applications of the disclosure is believed to be suitable to include but is not limited to the extraction of ionic, non-ionic, zweitter-ionic active principles, intermediates, metals or mixture thereof useful for human, veterinary or agricultural applications from modified or unmodified natural sources. Therefore, the present disclosure can be easily applied to an industrial scale.

While the invention is broadly as defined above, it will be appreciated by those persons skilled in the art that it is not limited thereto and that it also includes embodiments of which the following description gives examples.

EXAMPLES

The examples given are merely illustrative of the uses, processes and products claimed in this invention, and the practice of the invention itself is not restricted to or by the examples described.

Example 1 Extractor Details

In the extractor arrangement shown in FIG. 1, a cylindrical extractor column 1 (30 cm×200 cm) is provided with perforated supporting plate 7, the solid material inlet 2, perforated plate 4, projections 5, screw shaft 3, top column sealing plate 10, liquid inlet 8, supporting plate 16, first outlet 9 for extracting fluid containing active principle, second outlet 17 for removal of air, gas, steam, volatile matter, or residual extracting fluid, and lid 18 is constructed from stainless steel (SS316). Other material of construction can be used depending on type of application, solid material and extracting medium such as glass or glass lined extractor for acidic extracting fluid. The solid material inlet 2 is positioned at 5 cm below the top side of the extractor column 1; where as the liquid outlet 9 is located 5 cm below the solid material inlet 2. The screw shaft 3 is operated manually. A glass condenser assembly 13 is attached to the outlet 17 located 2 cm below the top side of the extractor column 1. Teflon pipe is used for connecting bottom liquid inlet 8 to pump extracting liquid to first outlet 9 to receiver and condensor 17. The perforations of the perforated plate 4 can be 0.5 mm to 50 mm diameter, preferably 0.5 mm to 20 mm diameter and covers about 0.001% to 20% of the surface area of the plate. They may or may not be in triangular or square pitch. The projections made can be cylindrical or square or any other shape known to skilled in art. Projections can be blunt end or sharp end. The perforations made on the plate can have same inner dimensions through the plate or may vary such as wider at side of plate and narrowing down towards the other end of the plate. The perforations also can be of other shape but covers the specified area on the plate. FIG. 2 a shows the side view of the perforated plate 4 with projections 5 and perforations 26. FIG. 2 b shows the vertical cross section of perforated plate 4 showing different types of perforations such as 26 a and 26 b.

FIGS. 1 and 3 provides the extractor where the extractor comprises a vertical vessel or column 1, a means to feed the solid material 2 into the extractor adjacent to the top side of the extractor 24, and a means to compact or pack the fed solid material into the extractor. The system used for compacting or packing of the solid materials into the extractor consists of a plate, preferably perforated 4 and with downward projections 5, and is operated through a screw type shaft 3 that can move up or down by an external drive 11, wherein the drive 11 is either manual drive or motorized drive or hydraulic system. The extracting liquid enters into the extractor through an inlet 8 located at the down side 25 (bottom end) of the extractor and passes through a perforated supporting plate 16, which distributes the liquid evenly in to the extractor, extracts the said active principles from the said solid material/s, and is taken out from the outlet 9 adjacent to the top side of the extractor column 1. The residual liquid remaining inside the extractor after complete extraction is removed by a hot air or steam passed into the extractor and is collected through the second outlet 17 adjacent to the top end of the extractor via a condenser system 13 attached to the said second outlet 17. The solids 6 packed in the extractor after complete extractions are removed from the bottom of the extractor, wherein the bottom plate 16 and perforated supporting plate 7 are opened manually using a hinge joint 15 or through a motorized system.

The extractor can also have an additional outer jacket. FIG. 3 provides jacketed compacted upflow solid liquid extractor. The jacket 27 has inlet 28 and outlet 29 for fluids such as hot water, cold water and steam. The cooling of the extractor can be done with chilled water or brine or other coolant available commercially.

Example 2

Extraction of Artemisinin from Artemisia annua Leaves The extractor was used for extraction of artemisinin from Artemisia annua leaves used as solid feed. Table 1 show results of extraction of artemisinin from Artemisia annua leaves obtained by using the extractor of the present disclosure.

TABLE 1 Summary of the parameters and results of artemisinin extraction using Compacted Upflow Solid Liquid Extractor (CUSLE) Parameter Result Artemisinin concentration in solid feed (% w/w) 0.26 Extractant flow rate (ml/min) 150 Quantity of solids (herbage) (Kg) 10 Total solvent volume used (Lit) 200 Artemisinin in extract (gm) 25.2 Artemisinin recovered (%) 96.9

10 Kg leaves of herb Artemisia annua were charged to the extractor through solid material inlet 2 and compacted by manually moving down the perforated plate 4 with projections 5. The extracting liquid (hexane) was pumped through the extractor at 150 ml/min flow rate in upward direction using a diaphragm pump. The extract containing artemisinin and other products was collected through the first outlet 9 (liquid outlet). After complete extraction, the residual extracting liquid form the herbage was removed by passing steam through the bottom inlet, and collecting the condensate from the condenser 13. Exhausted plant material was removed from the bottom of the extractor. The operation gave 96.9% artemisinin extraction from the leaves due to efficient contact of extractant with solid material (leaves) in the extractor.

Example 3 Extraction of Stevioside from Stevia rebaudiana Leaves

The extractor was used for extraction of Stevioside (polar compound) from Stevia rebaudiana leaves as solid feed. 13 Kg leaves of Stevia rebaudiana containing 9.1% of Stevioside were charged to the extractor through solid material inlet 2 and compacted by manually moving down the perforated plate 4 with projections 5. The extracting liquid (hot water) was pumped through the extractor at 150 cm/hr flow velocity in upward direction using a peristaltic pump. The extract containing Stevioside and other products was collected through the first outlet 9 (liquid outlet). After complete extraction, the residual extracting liquid form the solid material was removed by passing steam through the bottom inlet, and collecting the condensate from the condenser 13. Exhausted plant material was removed from the bottom of the extractor. A total of 1148 gms of Stevioside was obtained corresponding to 97.04% extraction efficiency due to efficient contact of extracting fluid with solid material (leaves) in the extractor.

Example 4

Extraction of Citronella Oil from Cymbopogon nardus and Cymbopogon winterianus Stem and Leaves

The extractor was used for extraction of citronella oil (volatile essential oil) from Cymbopogon nardus and Cymbopogon winterianus stem and leaves as solid feed. 15 Kg of the leaves and stems of Cymbopogon nardus and Cymbopogon winterianus containing 115 ml of essential oil were charged to the extractor through solid material inlet 2 and compacted by manually moving down the perforated plate 4 with projections 5. The extracting fluid (steam) was passed through the extractor at 250 cm/hr flow velocity in upward direction. The extract containing citronella oil and other products was collected through the second outlet 17 (residual extracting fluid) after condensation in condenser 13. Exhausted plant material was removed from the bottom of the extractor. The concentration of citronella oil extracted by the extracting liquid was 108 ml. The operation gave 94.0% citronella oil extraction due to efficient contact of extracting fluid with solid material (leaves and stems) in the extractor.

Example 5 Extraction of Psilocybin from Psilocybin Mushrooms

The extractor was used for extraction of Psilocybin (Zwitterionic compound) from Psilocybin mushrooms (Psilocybe cubensis and Psilocybe semilanceata) as solid feed. 12 Kg of Psilocybin mushrooms containing 10.3 gm of psilocybin were charged to the extractor through solid material inlet 2 and compacted by manually moving down the perforated plate 4 with projections 5. The extracting fluid (ethanol and methanol) was pumped through the extractor at 200 cm/hr flow velocity in upward direction using a peristaltic pump. The extract containing psilocybin and other products was collected through the first outlet 9 (liquid outlet). After complete extraction, the residual extracting liquid form the solid material was removed by passing steam through the bottom inlet, and collecting the condensate from the condenser 13. Exhausted mushrooms were removed from the bottom of the extractor. An yield of 9.8 gm of psilocybin was obtained corresponding to 95.2% extraction efficiency due to efficient contact of extracting fluid with solid material (mushrooms) in the extractor.

Example 6 Extraction of Soya Proteins from Glycine Max Seeds

The extractor was used for extraction of soya proteins (primary metabolite) from Glycine max seeds as solid feed. 10 Kg of Glycine max seeds containing 3.8 Kg of desired proteins were charged to the extractor through solid material inlet 2 and compacted by manually moving down the perforated plate 4 with projections 5. The extracting fluid, 50 mM acetate buffer of pH 4.5 was pumped through the extractor at 100 cm/hr flow velocity in upward direction using a diaphragm pump. The extract containing psilocybin and other products was collected through the liquid outlet 9. After complete extraction, the residual extracting liquid form the solid material was removed by passing steam through the bottom inlet, and collecting the condensate from the condenser 13. Exhausted seeds were removed from the bottom of the extractor. A total 3.62 kg of desired proteins were extracted. The operation gave 95.26% of desired soya proteins due to efficient contact of extracting fluid with solid material (seeds) in the extractor. 

1. An extractor for extracting active principle from solid materials using an extracting fluid, said extractor comprising; an extractor column (1), having a first side (22), a second side (23), a top side (24), and a bottom side (25); a top plate (10) for sealing the said extractor column (1), said top plate (10) positioned at said top side (24); a bottom plate (16) positioned at said bottom side (25) of said extractor column (1) by means a hinge arrangement (15); a solid material inlet (2) for feeding the solid material in said extractor column (1), wherein said solid material inlet (2) is located at said first side (22) towards said top side (24) of the extractor column (1); a extracting fluid inlet (8) is for introducing said extracting fluid in said extractor column (1), wherein said extracting fluid inlet (8) is located at said bottom side (25) of said extractor column (1), at least one perforated plate (4) having projections (5); wherein said perforated plate (4) is positioned inside said extractor column (1) by means of a screw shaft (3), wherein said screw shaft (3) passes through said top plate (10) by means of a leak proof joint (12); wherein said joint (12) allows rotation of said screw shaft (3); a perforated supporting plate (7) supported by said bottom plate (16), wherein said perforated supporting plate (7) distributes said extracting fluid evenly in said extractor column (1); a first outlet (9) positioned at said first side (22) towards said top side (24) of said extractor column (1) for collecting extracting fluid containing said active ingredient extracted from said solid matter; an optional second outlet (17) for removing volatile matter, air, gas steam or residual extracting fluid; and an optional condenser (13) to condense said volatile matter, air, gas steam or residual extracting fluid for collection, wherein said condenser (13) is connected to said second outlet (17).
 2. The extractor as claimed in claim 1), wherein said perforated plate (4) has perforations of diameter in the range of 0.5 mm-50 mm.
 3. The extractor as claimed in claim 1, wherein said perforated plate (4) has perforations of diameter in the range of 0.5 mm-20 mm.
 4. The extractor as claimed in claim 1, wherein said perforated plate (4) has perforations that cover % surface area of said perforated plate (4) in the range of 0.001% to 20%.
 5. The extractor as claimed in claim 1, wherein said projections (5) on said perforated plate 4 is in the range of 1-20 per square feet.
 6. The extractor as claimed in claim 1, wherein said projections (5) have diameter in the range of 2 mm-50 mm and length in the range of 20 mm-500 mm.
 7. The extractor as claimed in claim 1, wherein said projections (5) have blunt end, sharp end or combinations thereof.
 8. The extractor as claimed in claim 1, wherein said projections (5) is arranged on said perforated plate (4) at an angle in the range of 30°-90°.
 9. The extractor as claimed in claim 1, wherein said perforated supporting plate (7) has perforations of diameter in the range of 0.5 mm⁻¹⁰ mm.
 10. The extractor as claimed in claim 1, wherein said perforated supporting plate (7) has perforations that cover % surface area of said perforated supporting plate (7) in the range of 0.001% to 10%.
 11. The extractor as claimed in claim 1, wherein said screw shaft (3) is connected to an external drive (11) such as manual drive, motorized drive or hydraulic drive.
 12. The extractor as claimed in claim 1, wherein the solid material inlet (2) has a closing lid (18).
 13. The extractor as claimed in claim 1, wherein said solid material is a natural source, genetically manipulated, transgenic plant source, transgenic animal source, hybrid varieties of natural source.
 14. The extractor as claimed in claim 1, wherein said solid material is selected from a group consisting of plant source, herb source, shrub source, sea weeds source, animal and insect source.
 15. The extractor as claimed in claim 1, wherein said active ingredient is a primary metabolite or a secondary metabolite.
 16. The extractor as claimed in claim 1, wherein said active principle is selected from a group consisting of therapeutic drug, insecticide, growth regulator; flavor, perfumes, protein, peptide and nucleic acid.
 17. The extractor as claimed in claim 1, where said active principle is selected from a group comprising of stevioside, citronella oil, scopoletin, soya protein and psilocybin.
 18. The extractor as claimed in claim 1, wherein said extracting fluid is liquid, gas, air, steam or supercritical fluid.
 19. The extractor as claimed in claim 18, wherein said liquid is selected from a group consisting of polar solvent, non-polar solvent, ionic solvent or combinations thereof.
 20. The extractor as claimed in claim 19, wherein said polar solvent is selected from a group consisting of dimethyl formamide, tetrahydrofuran, water, acetonitrile, isopropanol, diethyl ether, 1-4 dioxane, alcohol/s and ketone/s.
 21. The extractor as claimed in claim 19, wherein said non-polar solvent is selected from a group consisting of hexane, heptanes, pentane, cyclohexane, benzene, toluene, carbon tetra chloride, butyl acetate, ethyl acetate, methylene dichloride, ethylene dichloride, chloroform and other chlorinated organic solvents.
 22. The extractor as claimed in claim 19, wherein said ionic solvent selected from a group consisting of N,N-dimethylethanolammonium octanoate (DMEA oct) and bis(2-methoxyethyl)ammonium bis(trifluoromethylsulfonyl)imide (BMOEA bst).
 23. The extractor as claimed in claim 18, wherein said extracting fluid is hexane, water, steam, hexane-methylene dichloride, ethanol or methanol.
 24. The extractor as claimed in claim 18, wherein said gas is supercritical carbon dioxide or supercritical water.
 25. A process of extracting active principle from solid material by an extracting fluid using said extracting column of claim 1, said process comprising; feeding said solid material into said extractor column (1) by said solid material inlet (2); compacting said solid material by said perforated plate (4) having said projections (5), wherein said compacting of solid material by said perforated plate (4) is performed by exerting pressure on said perforated plate (4) by said screw shaft (3); wherein said screw shaft (3) is driven by said external drive (11); introducing said extracting fluid into said extractor column (1) through said extracting fluid inlet (8); distributing said extracting fluid in the said extractor column (1) by said perforated supporting plate (7); contacting said compacted solid material with said extracting fluid; collecting said extracting fluid containing said active principle extracted from said solid material through said first outlet (9); optionally removing residual extracting fluid from said extractor column through said second outlet (17); wherein removing of said residual extracting fluid is performed by introducing steam or gas through said extracting fluid inlet 8 and closing said lid (18); ejecting out said residual extracting fluid in vapor form through said second outlet (17) and condensing in said condenser (13) for collecting said residual extracting fluid; and removing solid material from said extractor column (1) by opening said bottom plate (16).
 26. The process as claimed in claim 25, wherein said solid material is optionally preprocessed before feeding in said extractor column (1) by processes selected from a group comprising of pre-pulverized, pre-micronized, pre-grinded and pre-crushed.
 27. The process as claimed in claim 25, wherein said feeding of solid material in said extractor column (1) is performed manually or automatically by means of belt or bucket conveyors.
 28. The process as claimed in claim 25, wherein said extracting fluid has a flow velocity in the range of 10-10000 cm/hr.
 29. The process as claimed in claim 28, wherein said pressure is in the range of 0.5-50 bar.
 30. The process as claimed in claim 28, wherein said process is useful for extracting single or multiple active principle. 